Tooling
Tool and die services make us responsive, and allow us to control schedules, and maintain top quality.
Getting a profile or tube extrusion just right takes care and expertise. That’s why we encourage our customers to bring us into their project early in the process.
ACE, Absolute Custom Extrusions has access to the best tool & die resources available. The expertise to build the most sophisticated, streamlined and serviceable dies is at our fingertips. Modern electrical discharge machining (EDM) technology enhances tool quality and cost-effectiveness. Whatever your design specifications, our engineers and other qualified staff members are ready to assist you in making the wisest product choice. We'll help answer your questions regarding overall effectiveness and propose viable alternatives if necessary.
Working with an experienced designer before a product is specified can help reduce pre-production and in-production costs.
Die Engineering and Profile Development
Profile tooling requires a balance of geometry, material flow control, and thermal management. Engineers evaluate resin viscosity, cooling rates, and expected shrink behavior to design dies that produce stable shapes without distortion. This includes calibrators, sizing fixtures, and support components that guide the profile as it exits the die. Early involvement in the design phase helps align functional requirements with manufacturability, reducing adjustments during sampling and minimizing production delays.
Manufacturing Methods for Precision Tooling
Modern toolmaking relies on machining technologies that support tight tolerances and smooth internal surfaces. Electrical discharge machining (EDM), CNC milling, and polishing techniques are used to create flow paths that reduce shear, prevent hang up points, and maintain consistent melt distribution. These methods allow complex shapes to be produced with repeatable accuracy, supporting both simple tubing and intricate multi cavity profiles.
Tool Maintenance and Lifecycle Management
Extrusion dies experience thermal cycling, pressure, and continuous material flow, all of which influence long term performance. Routine inspection, cleaning, and refurbishment help maintain dimensional accuracy and extend tool life. Proper maintenance reduces downtime, improves surface quality, and ensures that profiles remain consistent across repeated production runs. Lifecycle management also includes evaluating wear patterns to refine future tooling designs.
FAQ
What Factors Influence the Design of an Extrusion Die?
Material viscosity, wall thickness requirements, cooling behavior, and profile geometry all play a role in determining die design.
How Does Tooling Affect Production Efficiency?
Well engineered tooling improves melt distribution, reduces adjustments during startup, and supports stable, continuous extrusion with fewer interruptions.
Why Is Early Tooling Input Helpful During Product Development?
Early collaboration helps align design intent with manufacturability, reducing revisions and improving the accuracy of the first production samples.
How Long Does an Extrusion Die Typically Last?
Tool life depends on material type, production volume, and maintenance practices. Regular inspection and cleaning extend service life and maintain dimensional consistency.
Please contact your ACE sales representative at 414-332-8133 or email to discuss products and services.
Shaping the World with Plastic Extrusions for Over 35 Years